Wire harness mounting structure for motor vehicle door

ABSTRACT

A wire harness mounting structure for a motor vehicle door comprising a door frame and planar mounting means, detachably attached to said door frame at an internal side of its motor vehicle, having a wire harness mounted thereon and extending in a plane generally parallel to the door frame. The mounting means is either in the form of a covering board, or a combination of the covering board and an internal side board mounted between the vehicle door frame and the covering board, and, is either integrally formed with the covering board or independently, rigidly formed as in the case of an internal side board. The wire harness is terminated at the hinge mounting end of the door frame in a bundled leading-out portion which in one embodiment is fixed to the door frame by a waterproof grommet which surrounds the leading-out portion and is supported in a groove formed in the hinge mounting end of the frame at a corner portion defined by the inner side surface of the door frame and the hinge mounting end of the frame.

This application is a division of application Ser. No. 07,233,912 filedon Aug. 16, 1988, now U.S. Pat. No. 4,907,836 which is a continuation ofapplication Ser. No. 767,156 filed Aug. 19, 1985 (now abandoned).

BACKGROUND OF THE INVENTION

This invention relates to a wire harness mounting structure to be usedfor an electric circuit of a motor vehicle door.

Generally, a door of a motor vehicle comprises, as main componentmembers thereof, an external door frame and an internal covering boardusually called a trim cover. As shown in FIG. 1, a door wire harness Win bundle form is disposed in a space within a door frame A. The doorwire harness W is provided at its end portions with branch wires w1, w2,w3, w4, w5, . . . respectively, having connectors c1, c2, c3, c4, c5 . .. attached thereto. The branch wires w1 and w2 are connected to a powerwind motor and a solenoid for locking an automatic door within the doorframe A, respectively, through the connectors c1 and c2. The branchwires w3, w4, and w5 are drawn out through a working window H andconnected to a cartesi-lamp, trunk opening switch, power wind switch,etc., provided on a trim cover B by the connectors c3, c4 and c5,respectively. The door wire harness W is drawn out through a grommet Gand connected to a cowl side harness at the vehicle body side by aconnector C.

The door wire harness W is inserted in the door frame A through theworking window H, and at the same time, the grommet G, which was fixedthereto in advance, is drawn out with its connector C through a hole ofthe door frame A, and similarly, a clamp K, which was likewise fixedthereto in advance, is engaged in a hole formed in the bottom portion ofthe door frame A, thereby fixing the door wire harness W to apredetermined wiring path. The connectors c1 and c2 are then connectedto electric equipment within the door frame A, and the connectors c3, c4and c5 are connected to electric equipment of the trim cover B.Thereafter, the trim cover B is fixed to the door frame A. However, inthis conventional method, much time is required to insert the door wireharness W in the door frame A, and also to secure a clamp K to the doorwire harness W. Securing the clamp K to the wire harness W is oftencarried out blindly in a narrow space. This considerably slows down theproduction of motor vehicles in the production line thereof.

In view of the above, there has been a proposal in Japanese utilitymodel application No. 58(1983)-5397, wherein a wire harness is attachedin advance to a sealing sheet, which is mounted to the door frame, inorder to reduce labor and time for wiring the door wire harness W withinthe door frame.

According to this method after the sealing sheet is attached to the doorframe through its peripheral portion, connectors of the branch wires areconnected to electric equipment within the door frame. Thereafter,connectors of the remaining branch wires are connected to electricequipment of the trim cover and at the same time, the trim cover isfixed to the door frame. In this case, connection of the branch wires inthe production line of motor vehicles is left undone. Since the sealingsheet is formed of a soft synthetic resin material, much time isrequired to mount it, and usually requires specialized bonding means. Itis also extremely difficult to maintain the shape of the sheet when itis stored or transported often resulting in entangled branch wires.Also, retaining the wire harness merely by the sealing sheet is notsufficient, especially when it is used in circumstances under severevibrations. Accordingly, it must be fixed to the door frame in advance,again requiring additional labor.

Another related art is disclosed in Japanese utility model earlydisclosure No. 56(1981)-97814, wherein one end portion of a conventionalwire harness for a motor vehicle door is drawn out from the door througha grommet, reaches the vehicle body side from the door side byengagement with the respective holes, and connects to a cowl sideharness within the vehicle body through a connector.

However, in the above-mentioned related art wherein the door wireharness is mounted to the door frame of a motor vehicle through thegrommet, the end portion of the wire harness is thrusted through thethrusting hole formed in the door through the grommet, and thereafter,it is further required to be thrusted through another thrusting holeformed in the vehicle body side. Accordingly, this thrusting action andthe requirement that it be performed twice, proves troublesome and,again, considerably slows down the production of motor vehicles in theproduction line thereof.

The present invention eliminates the above-mentioned inconveniencesinherent in the prior art.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide a wireharness mounting structure for a motor vehicle door, wherein the doorwire harness can be mounted easily and promptly in the production lineof motor vehicles.

Another object of the present invention is to provide a wire harnessmounting structure for a motor vehicle door, wherein the wire harness isflatly mounted to mounting means, including a covering board, so that itcan be wired linearly and by way of the shortest distance.

A further object of the present invention is to provide a wire harnessmounting structure for a motor vehicle door, wherein the branch wires ofthe wire harness are not entangled at the time when the mounting means,including the cover with the door wire harness attached thereto, istransported, stored and mounted to the door frame.

A still further object of the present invention is to provide a wireharness mounting structure for a motor vehicle door, wherein the doorwire harness can be held in a stable position, even in circumstanceswhere it is subject to severe vibration.

In order to achieve the above objects, there is essentially provided awire harness mounting structure for a motor vehicle door comprising adoor frame and planar mounting means detachably attached to said doorframe at an internal side of the motor vehicle, having a wire harnessmounted thereon, said means extending in a plane generally parallel tosaid door frame. The mounting means is either in the form of a coveringboard, or a combination of the covering board and an internal side boardmounted between the vehicle door frame and the covering board, and iseither integrally formed with the covering board, or rigidly formedindependent of the board, as in the case of an internal side board.

The above and other objects and attendant advantages of the presentinvention will be apparent to those skilled in the art from a reading ofthe following description and claims, which in conjunction with theaccompanying drawings, constitute part of this specification.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of a conventional wire harnessmounting structure for a motor vehicle door.

FIG. 2 is an exploded perspective view of a wire harness disposed on acovering board in relation to a motor vehicle door to which the board isto be mounted according to a first embodiment of the present invention.

FIG. 3 is a perspective view showing the door wire harness of FIG. 2 onthe covering board already mounted to the motor vehicle door.

FIG. 4 is an exploded perspective view of a wire harness disposed on acovering board in relation to a motor vehicle door to which the board isto be mounted according to a second embodiment of the present invention.

FIG. 5 is a perspective view showing the door wire harness of FIG. 4 onthe covering board already mounted to the motor vehicle door.

FIG. 6 is an exploded perspective view of a wire harness disposed on awire harness wiring board in relation to a motor vehicle door to whichthe board is to be mounted according to a third embodiment of thepresent invention.

FIG. 7 is an exploded perspective view showing the door wire harness ofFIG. 6 on the wiring board already mounted to the covering board.

FIG. 8 is a perspective view of the covering board of FIG. 7 alreadymounted to the door frame.

FIG. 9 is a perspective view of a modified embodiment of the above,wherein the wiring board is directly mounted to the door frame.

FIG. 10 is a perspective view of the wiring board of FIG. 9 when viewedfrom the back thereof.

FIG. 11 is an exploded front view of a further modified embodiment.

FIG. 12 is a sectional view taken on line XII--XII of FIG. 11.

FIG. 13 is a perspective view of a still further modified embodiment.

FIG. 14 is an exploded perspective view of a wire harness disposed on acovering board formed of an electric equipment mounting board sectionand an electric equipment non-mounting board section in relation to amotor vehicle door to which the board is to be mounted according to afourth embodiment of the present invention.

FIG. 15 is a perspective view showing one stage of the mounting processof FIG. 14.

FIG. 16 is a perspective view showing the mounting work.

FIG. 17 is an exploded perspective view of a wire harness disposed on aninternal side board in relation to a covering board and a motor vehicledoor to which the side board is to be mounted according to a fifthembodiment of the present invention.

FIG. 18 is a perspective view of the internal side board already mountedto the door frame.

FIG. 19 is a perspective view showing a modification of the aboveinternal side board.

FIG. 20 is a detailed illustration showing a connector portion of FIG.19.

FIG. 21 is an exploded perspective view showing a further modifiedembodiment of the internal side board.

FIG. 22 is a perspective view of the above modified internal side boardalready mounted to the door frame.

FIG. 23 is an exploded perspective view according to a sixth embodimentof the present invention, of a wire harness disposed on a mounting boardin relation to a covering board and a motor vehicle door to which themounting board is to be mounted.

FIG. 24 is a perspective view of the mounting board of FIG. 23 alreadymounted to the door frame.

FIG. 25 is a plan view of the mounting board of FIG. 23.

FIG. 26 is an exploded perspective view according to a seventhembodiment of the present invention, of a wire harness disposed on amounting board in relation to a covering board and a motor vehicle doorto which the mounting board is to be mounted.

FIG. 27 is a perspective view of the mounting board of FIG. 26 alreadymounted to the covering board.

FIG. 28 is a perspective view showing one example of element wires whichform the wire harness.

FIG. 29 is a plan view of the mounting of FIG. 26.

FIG. 30 is a sectional view of the above seventh embodiment, wherein thedoor frame, mounting board, and covering board are shown separated.

FIG. 31 is an exploded perspective view of a modified embodiment of theharness of FIG. 26.

FIG. 32 A and FIG. 32 B are perspective views of one example of aconnector mounting structure.

FIG. 33 is an exploded perspective view of a wire harness disposed on acovering board in relation to a motor vehicle door to which the board isto be mounted according to an eighth embodiment of the presentinvention.

FIG. 34 is a perspective view showing the door wire harness of FIG. 33on the covering board already mounted to the motor vehicle door.

FIG. 35 is a sectional view of the connecting section of a connector ofFIG. 34.

FIG. 36 is a plan view, partly exploded, of a connector connectingsection according to a modified embodiment of the invention;

FIG. 37 is an exploded perspective view of a wire harness disposed on acovering board in relation to a motor vehicle door to which the board isto be mounted according to a ninth embodiment of the present invention.

FIG. 38 is a perspective view of the wire harness of FIG. 37 alreadymounted to the door frame.

FIG. 39 A and FIG. 39 B are perspective views showing an exploded stateof a portion of the wire harness of FIG. 37, and a mounted state of theportion thereof, respectively.

FIG. 40 is an exploded perspective view showing a modified embodiment ofthe harness of FIG. 37.

FIG. 41 is an exploded perspective view showing a still further modifiedembodiment.

FIG. 42 is a perspective view showing a wire harness prepared through amodified method before mounting it to the mounting means used in theinvention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Preferred embodiments of the present invention will be describedhereunder with reference to the accompanying drawings, wherein likereference numerals denote like or corresponding parts throughout severalsheets of the drawings.

Referring to FIGS. 2 and 3, a first embodiment of the invention will bedescribed. In FIG. 2, A denotes a door frame for a motor vehicle door,and B denotes a covering board to be attached to the internal sidethereof. The covering board B is provided with conductors for a doorwire harness W flatly disposed thereon in parallel with one another bybonding agents, adhesive tapes, or other similar means.

The door wire harness flatly disposed is provided with branch wires w1,w2, w3, w4, w5 . . . having at the end portions thereof with connectorsc1, c2, c3, c4, c5, . . . and is disposed in such a manner as to bespaced apart from the covering board B. The door wire harness W isprovided at its connecting end, toward a cowl side harness at a vehiclebody side, with a bundled leading-out portion W'. The bundledleading-out portion W' is provided with a water proofing portion by agrommet G. The leading-out portion W' may be formed with a connector,and the connector may also serve as a water proofing portion.

The flat-shaped wire harness W may use elongated materials or rodmaterials other than normal electric wires. When the elongated materialsor rod materials are used, they are connected to the branch wires w1, w2. . . and the electric wires of the bundled leading-out portion throughterminals by welding or other similar means.

The covering board B is provided with electric equipment cartesi-lamp 1,trunk open switch 2, and power wind switch 3, to which the branch wiresw1, w2 and w3 are connected in advance through the connectors c1, c2 andc3.

The covering board B in the foregoing state is combined with the doorframe A of a motor vehicle in the production line, and the branch wiresw4 and w5 are connected to a power wind motor 4 and an automatic doorlocking solenoid 5 within the door frame A through the connectors c4 andc5. At the same time, the water proofing portion, such as the grommet Gin the bundled leading-out portion W', is put in alignment withleading-out hole 6. Thereafter, the covering board B is fixed to thedoor frame A.

The structure of the leading-out hole 6 is such that one side of thecovering board B is partly cut out. It is also possible to push,therein, such a water-proofing portion as the grommet G etc., in thebundled leading-out portion W' from sideward of the leading-out hole 6.

Referring now to FIGS. 4 and 5, a second embodiment of the presentinvention will be described. In FIG. 4, A denotes a door frame in amotor vehicle door, and B denotes a covering board to be attached to theinternal side thereof. The covering board B is divided into twoportions; one is a wire harness wiring board section B1, and the otheris a wire harness non-wiring board section B2. The wire harness wiringboard portion B1 is provided with conductors for a door wire harness Wflatly disposed thereon in parallel with one another by bonding agents,adhesive tapes, or other similar means.

The door wire harness flatly disposed is provided with branch wires w1,w2, w3, w4, w5 . . . having at the end portions thereof connectors c1,c2, c3, c4, c5 . . . and is disposed in such a manner as to be spacedapart from the wire harness wiring board section B1. The door wireharness W is provided at its connecting end, toward a cowl side harnessat a vehicle body side, with bundled leading-out portion W'. The bundledleading-out portion W' is provided with a water proofing portion by agrommet G. The leading-out portion W' may be formed with a connector,and the connector can also be provided with a water proofing cover.

The flat-shaped wire harness W may use elongated materials or barmaterials other than normal electric wires. When the elongated materialsor bar materials are used, they are connected to the branch wires w1, w2. . . and the electric wires of the bundled leading-out portion throughterminals by welding or other similar means.

The wire harness wiring board portion B1 is engaged in a hole 7 formedin the wire harness non-wiring board portion B2, and fixed thereto by afixture 8.

The covering board B is provided with electric equipment cartesi-lamp 1,trunk opening switch 2, and power wind switch 3, to which the branchwires w1, w2 and w3 are connected in advance through the connectors c1,c2 and c3.

The covering board B in the foregoing state is combined with the doorframe A of a motor vehicle in the production line of motor vehicles, andthe branch wires w4 and w5 are connected to a power wind motor 4 and anautomatic door locking solenoid 5 within the door frame A through theconnectors c4 and c5. At the same time, a water proofing portion , suchas the grommet G in the bundled leading-out portion W' is put inalignment with leading-out hole 6. Thereafter, the covering board B isfixed to the door frame A.

Referring now to FIGS. 6 through 8, a third preferred embodiment of theinvention will be described. In FIG. 6, the wire harness wiring boardsection B1 is provided with conductors for a door wire harness W flatlydisposed thereto in parallel with one another by bonding agents,adhesive tapes, or other similar means.

The door wire harness flatly disposed is provided with branch wires w1,w2, w3, w4, w5 . . . having at the end portions thereof connectors c1,c2, c3, c4, c5, . . . , and is disposed in such a manner as to be spacedapart from the wire harness wiring board section B1. The door wireharness W is provided at its connecting end toward a cowl side harnessat a vehicle body side, with bundled leading-out portion W'. The bundledleading-out portion W' is provided with a water proofing portion by agrommet G.

The flat-shaped wire harness W may use elongated materials or barmaterials other than normal electric wires. When the elongated materialsor bar materials are used, they are connected to the branch wires w1, w2. . . and the electric wires of the bundled leading-out portion W'through terminals by welding or other similar means.

In this embodiment, the wire harness wiring board section B1 is engagedin a hole 7 formed in the covering board B, which is to be attached tothe internal side of a motor vehicle door, and fixed thereto by afixture 8 (FIG. 7).

The covering board B is provided with electric equipment cartesi-lamp 1,trunk opening switch 2, and power wind switch 3, to which the branchwires w1, w2 and w3 are connected in advance through the connectors c1,c2 and c3.

The covering board B in the foregoing state is combined with the doorframe A of a motor vehicle in the production line of motor vehicles, andthe branch wires w4 and w5 are connected to a power wind motor 4 and anautomatic door locking solenoid 5 within the door frame A through theconnectors c4 and c5. At the same time, a water proofing portion, suchas the grommet G in the bundled leading-out portion W', is put inalignment with leading-out hole 6. Thereafter, the covering board B isfixed to the door frame A (FIG. 8).

FIGS. 9 and 10 illustrate a modified embodiment of the wiring board. Inthis modified embodiment, a wire harness wiring board section B1 isfixed to the internal side of the door frame A. In this case, the wireharness wiring board section B1, made of a synthetic resin material, isintegrally formed at its rear surface with a plurality of elasticretaining nails 9 as shown in FIG. 10. By inserting the elasticretaining nails 9 in retaining holes formed at predetermined positionsin the door frame A in advance, the wire harness wiring board section B1can be mounted to the door frame A easily and rapidly.

For water-proofing purposes, the wire harness wiring board section B1may be fixed to a synthetic resin sheet interposed between the doorframe A and the covering board B by bonding means.

FIGS. 11 and 12 illustrate another modified embodiment of the wiringboard, wherein a wire harness wiring board section B1 is provided with aplurality of knobs B1a, B1b, B1c . . . B1n, and the covering board B isformed with a plurality of retaining holes Ba, Bb, Bc, Bn correspondingto the knobs B1a, B1b, B1c . . . B1n. The wire harness wiring boardsection B1 with the wire harness flatly disposed thereon in advance isfixed by means of engagement between the knobs B1a . . . B1n and theretaining holes Ba-Bn.

In a still further modified embodiment shown in FIG. 13, the wireharness wiring board section B1 is formed of a thin plate made of asynthetic material. In this modified embodiment, the wire harness wiringboard section B1 is formed with a slit 10 which suitably fits with anuneven portion at a location where the board portion B1 is to be placed.

Referring now to FIGS. 14 and 16, a fourth embodiment of the presentinvention will be described. In FIG. 14, A denotes a door frame in amotor vehicle door, and B denotes a covering board to be attached to theinternal side thereof. The covering board B is divided into twoportions; one is an electric equipment mounting board section BI and theother is an electric equipment non-mounting board section BII. The upperelectric equipment mounting board section BI is provided with conductorsfor a door wire harness W flatly disposed thereon in parallel with oneanother by bonding agents, adhesive tapes, or other similar means.

The door wire harness W flatly disposed is provided with branch wiresw1, w2, w3, w4, w5 . . . having at the end portions thereof connectorsc1, c2, c3, c4, c5 . . . , and is disposed in such a manner as to bespaced apart from the electric equipment mounting board section BI. Thedoor wire harness W is provided at its connecting end, toward a cowlside harness at a vehicle body side, with a bundled leading-out portionW'. The bundled leading-out portion W' is provided with a water proofingportion G such as a grommet. The leading-out portion W' may be formedwith a connector, which can also be provided with a water proofingcover.

The flat-shaped wire harness W may use elongated materials or barmaterials other than normal electric wires. When the elongated materialsor bar materials are used, they are connected to the branch wires w1, w2and the electric wires of the bundled leading-out portion throughterminals by welding or other similar means.

The electric equipment mounting board section BI is provided with atrunk opening switch 2, and a power wind switch 3, to which the branchwires w2 and w3 are connected in advance through the connectors c2 andc3.

The electric equipment mounting board section BI in the foregoing stateis combined with the door frame A of a motor vehicle in the productionline, and the branch wires w4 and w5 are connected to a power wind motor4 and an automatic door locking solenoid 5 within the door frame A fromworking windows H, through the connectors c4 and c5. At the same time,the water proofing portion, such as the grommet G in the bundledleading-out portion W', is put in alignment with leading-out hole 6.Thereafter, the electric equipment mounting board section BI is fixed tothe door frame A. Then, the working windows H are shut by fixing theelectric equipment non-mounting board section BII to the door frame A.

Referring now to FIGS. 17 and 18, a fifth embodiment of the presentinvention will be described. In FIG. 17, A denotes a door frame in amotor vehicle door, and B denotes a covering board to be attached to theinternal side thereof. The door frame A has a separated internal sideboard portion A1.

The internal side board section A1 is formed of a metallic or syntheticresin material. The internal side board section A1 is provided at itsone side surface with the respective conductors for a main wire portionof a door wire harness W, flatly attached thereto in parallel with oneanother by bonding agents, adhesive tapes, or other similar means.

The door wire harness W flatly disposed is provided with branch wiresw1, w2, w3, w4, w5 . . . having at end portions thereof connectors c1,c2, c3, c4, c5 . . . and is disposed in such a manner as to be spacedapart from the internal side board section A1. The door wire harness Wis provided at its connecting end, toward a cowl side harness at avehicle body side, with a bundled leading-out portion W'. The bundledleading-out portion W' is provided with a water proofing portion G, suchas a grommet. The leading-out portion W' may be formed with a connectorwhich can also be provided with a water proofing cover.

The flat-shaped wire harness W may use elongated materials or barmaterials other than normal electric wires. When the elongated materialsor bar materials are used, they are connected to the branch wires w1, w2. . . , and the electric wires of the bundled leading-out portionthrough terminals by welding or other similar means.

The covering board B is provided with a cartesi-lamp 1, a trunk openingswitch 2, and a power wind switch 3, and the door frame A is provided atits inside with a power wind motor 4 and an automatic door solenoid 5.

The internal side board portion Al in the foregoing state is combinedwith the door frame A of a motor vehicle in the production line of motorvehicles, and the branch wires w4 and w5 are connected to a power windmotor 4 and an automatic door locking solenoid 5 within the door frame Afrom working windows H through the connectors c4 and c5. At the sametime, a water-proofing portion such as the grommet G, in the bundleleading-out portion W' is put in alignment with leading-out hole 6.Thereafter, while the branch wires w1, w2 and w3 are being connected tothe cartesi-lamp 1, trunk opening switch 2, and power wind switch 3, thecovering board B is fixed to the door frame A. At this time, theleading-out hole 6 is shut by the covering board B. In this embodiment,the internal side board portion A, is detachably mounted on the doorframe A. However, said internal side board portion A, may be integral tothe door frame A.

In a modified embodiment as shown in FIG. 19, the door wire harness Wand the branch wires w1 through w5 use an elongated material or barmaterial, and are integrally molded to the inside of the internal sideboard section A1 which is made of a synthetic resin material. Theconnectors c1 through c5, at the end portions of the respective branchwires w1 through w5, are connected to both sides of the internal sideboard section A1 in such a manner as to be facing outward.

As shown in FIG. 20, the end portion 17a of each of the elongatedmaterials 17 is bent and projected outward from the outer surface of theinternal side board section A1. Accordingly, by combining the connectorsc1, etc. thereto, they function as terminal metal pieces.

In the above case, the connectors which are to be interconnected to theelectric equipment within the door frame and the covering board B arelocated in opposite relation. Accordingly, the above-mentioned electricequipment is immediately connected through the connectors at the timewhen the internal side board A1 or the covering board B is mounted tothe door frame.

According to a modified embodiment in FIG. 21, the internal side boardsection A' of the door frame A is integrally formed in the same manneras the conventional art. In this embodiment, a smaller internal sideboard section A1 is fixed to the outer surface of the internal sideboard section A'. The smaller internal side board section A1 is attachedwith the door wire harness W in the same manner as in the precedingembodiment. The wire harness W has branch wires w1 through w5 providedat the end portions thereof with connectors c1 through c5.

The internal side board section A' is formed with a cut-out portion 18for receiving the smaller internal side board section A1 therein.

Referring now to FIGS. 23 and 25, a sixth embodiment of the presentinvention will be described. In FIG. 23, a mounting board X is providedat its one surface with the respective conductors for a door wireharness W flatly disposed thereon in parallel with one another bybonding agents, adhesive tapes, or other similar material. At the sametime, the mounting board X is firmly attached with a main connector C atone end portion of the door wire harness W, and also with connectors c1and c2 of branch wires w1 and w2 with the connecting portions thereoffacing outward with respect to the door frame A. On the other hand, themounting board X is firmly attached at its other surface with connectorsc3 and c4 of branch wires w3 and w4 facing outward with respect to thecovering board.

The door frame A is firmly attached at its internal surface with aconnector C' at an end portion of a cowl side harness W' from thevehicle body, a connector c4 for a power wind motor 4 and a connector c5for an automatic door locking solenoid 5 disposed at predeterminedpositions. The covering board B is firmly attached at its rear surfacewith a connector c2' for a trunk opening switch 2 and a connector c3'for a power wind switch 3 disposed at predetermined positions.

The mounting board X in the foregoing state is firmly attached to apredetermined position on the door frame A by suitable retaining means.At the same time, the corresponding connectors are inter-connectedrespectively. Thereafter, the covering board B is mounted to the doorframe A and the remaining connectors c3 and c3', and c4 and c4' areinterconnected, respectively.

Referring to FIGS. 26 through 30, a seventh embodiment of the presentinvention will be described. In FIG. 26, respective conductors l of adoor wire harness W are buried in a mounting plate X made of a syntheticresin material either in parallel or multi-layer form. The conductors lare formed of elongated materials or bar materials such as bus bars. Asshown in FIG. 28, the conductors l each has a bent terminal portion l1at its end portion.

The bent terminal portions l1 of the plurality of conductors l areconcentratedly exposed from the mounting board X. A main connector C atone end portion of the door wire harness W, and connectors c4 and c5which are to be attached to the branch wire portion are formed on thesurface opposite to the door frame A, while connectors c2 and c3 areformed on the other surface thereof, opposite to the covering board B.

The door frame A is firmly attached at its internal surface with aconnector C' attached to an end portion of a cowl side harness W' fromthe vehicle body, a connector c4 for a power wind motor 4 and aconnector c5 for an automatic door locking solenoid 5 disposed atpredetermined positions. The covering board B is firmly attached at itsrear surface with a connector c2 for a trunk opening switch 2 and aconnector c3 for a power wind switch 3, disposed at predeterminedpositions.

The mounting board X in the foregoing state is firmly secured to apredetermined position on the covering board B by screws 25 as shown inFIG. 27. At the same time, the corresponding connectors c2 and c2', andc3 and c3' are inter-connected respectively. Thereafter, the coveringboard B is mounted to the door frame A and the other connectors C andC', c4 and c4', and c5 and c5' are interconnected, respectively.

In the above embodiment, an arm supporting portion 26 serving as aswitch unit, and including switches 2 and 3, is formed on the coveringboard B in advance. However, the arm supporting portion 26 may be fixedto the covering board B at the same time when the mounting board X isattached to the covering board B by bolts or other retaining means.

FIG. 31 illustrates a modified embodiment, in which a mounting board X,made of a metallic material or a synthetic resin material, is flatlyfixed to its one surface with respective conductors l of a door wireharness W in parallel relation by bonding agents, adhesive tapes, orother similar means. At the same time, the mounting board X is firmlyattached with a main connector C at one end portion of the door wireharness W and also with connectors c4 and c5 of branch wires w4 and w5,with the connecting portions thereof facing outward with respect to thedoor frame A. On the other hand, the mounting board X is firmly attachedat its other surface with connectors c2 and c3 of branch wires w2 and w3facing outward with respect to the covering board B.

The door frame A is firmly attached at its internal surface with aconnector C', attached to an end portion of a cowl side harness W' fromthe vehicle body, a connector c4 for a power wind motor 4 and aconnector c5 for an automatic door locking solenoid 5, disposed atpredetermined positions. The covering board B is firmly attached at itsrear surface with a connector c2 for a trunk opening switch 2 and aconnector c3 for a power wind switch 3, disposed at predeterminedpositions.

The mounting board X in the foregoing state is firmly secured to apredetermined position on the covering board B by screws 25. At the sametime, the corresponding connectors C and C', c4 and c4', and c5 and c5'are interconnected, respectively. Thereafter, the covering board B ismounted to the door frame A and the remaining connectors c2 and c2', andc3 and c3' are inter-connected, respectively.

FIGS. 32A and B illustrate one example of a mounting structure of aconnector C to be mounted to an internal surface board 30. The connectorC is formed with a mounting groove Ca at an intermediate position alongthe outer peripheral portion thereof and is provided at both oppositesurfaces with a locking arm Cb having its free end retaining portion Ccenergized toward the groove portion Ca. By pushing the connector C intoa retaining hole Xb through a comparatively large cut-out portion Xaformed in the internal surface board X, both edge board portions Xcengage the groove portion Ca. At this time, the retaining portion Cc ofthe locking arm Cb is engaged in the hole Xd of the surface board X,thereby locking the connector in place.

Referring now to FIGS. 33 and 34, an eighth embodiment of the presentinvention will be described. In FIGS. 33 and 34, A denotes a door framein a motor vehicle door, and B denotes a covering board to be attachedto the internal side thereof. The covering board B is provided with therespective conductors for a door wire harness W flatly disposed thereonin parallel with one another by bonding agents, adhesive tapes, or othersimilar means.

The door wire harness W flatly disposed is provided with branch wiresw1, w2, w3, w4, w5 . . . having at end portions thereof connectors c1,c2, c3, c4, c5 . . . , and disposed in such a manner as to be spacedapart from the covering board B. The door wire harness W is provided atits connecting end toward a cowl side harness at a vehicle body side,with a bundled leading-out portion W'. The bundled leading-out portionW' is provided with a main connector C, which is provided with a waterproofing cover.

The flat-shaped wire harness W may use elongated materials or barmaterials other than normal electric wires. When the elongated materialsor bar materials are used, they are connected to the branch wires w1, w2. . . and the electric wires of the bundled leading-out portion throughterminals by welding or other similar means.

The covering board B is provided with a cartesi-lamp 1, a trunk openingswitch 2, and a power wind switch 3, to which the branch wires w1, w2and w3 are connected in advance through the connectors c1, c2 and c3.

The covering board B in the foregoing state is combined with the doorframe A of a motor vehicle in the production line of motor vehicles, andthe branch wires w4 and w5 are connected to a power wind motor 4 and anautomatic door locking solenoid 5 within the door frame A from workingwindows H, through the connectors c4 and c5. At the same time, the mainconnector attached to the bundled leading-out portion W' is pushedsideways into a leading-out hole 6 in order to have a retaining board 6aengage groove 40. Thereafter, the covering board B is fixed to the doorframe A.

In the foregoing state, a main connector C', is disposed within thegrommet G for the cowl side harness W' inserted in an inserting hole 49formed in the vehicle body D, and is thereby connected to the mainconnector C attached to an end portion of the door frame A.

FIG. 35 illustrates a section of the main connectors C and C' inoperative engagement with each other. The main connector C is providedwith a water-proofing cover 51 made of a rubber material. An annularprojection Gal formed on a connector water-proofing cover portion Ga ofthe grommet G is engaged in an annular groove 51a formed in thewater-proofing cover 51. The grommet G is formed of a rubber materialextending in a series from a stationary cylindrical portion Gb withrespect to the wire harness, through an annular engaging portion Gc andan expanding and contracting according-like portion Gd, to the connectorwater-proofing cover portion Ga.

In FIG. 36, the main connector C at the door side is fixed to an endportion of the door frame A facing the internal surface side thereof. Anend portion of the grommet G in the cowl side wire harness W' isprovided with a connector water proofing cover portion Ga bent by 90°with respect to the extending direction of the grommet G.

In the above embodiment, the main connector is fixed to an end portionof the door wire harness, and the vehicle body side wire harness isdrawn out from an inserting hole through a grommet, and the mainconnector at the end portion thereof is connected to the main connectorfixed to the door. Alternatively, the main connector at the end portionof the vehicle body side wire harness may be fixed, and the drawing-outend portion of the door wire harness may be connected thereto.

Referring now to FIGS. 37 through 39, a ninth preferred embodiment ofthe invention will be described. In FIG. 37, A denotes a door frame fora motor vehicle door, and B denotes a covering board to be attached tothe internal side thereof. The covering board B is provided withconductors for a door wire harness W flatly disposed thereon in parallelwith one another by bonding agents, adhesive tapes, or other similarmeans.

The door wire harness flatly disposed is provided with branch wires w1,w2, w3, w4, w5 . . . having at end portions thereof connectors c1, c2,c3, c4, c5 . . . , and is disposed in such a manner as to be spacedapart form the covering board B. The door wire harness W is provided atits connecting end, toward a cowl side harness at a vehicle body side,with a bundled leading-out portion W'. The bundled leading-out portionW' is provided with a water proofing portion such as a grommet G. Thedoor side end portion of the grommet G is formed with a engaging portionG' formed of large and small flanges g1 and g2 with a groove portion g3formed therebetween. The internal side flange g1 is formed at its upperand lower sides with mounting holes g5, opposite to mounting holes 66a,which are formed in a mounting groove portion 66 of the door frame A.

The flat-shaped wire harness W may use elongated materials or rodmaterials other than normal electric wires. When the elongated materialsor rod materials are used, they are connected to the branch wires w1, w2etc. and the electric wires of the bundled leading-out portion W'through terminals by welding or other similar means.

The covering board B is provided, with electric equipment cartesi-lamp1, trunk opening switch 2, and power wind switch 3, to which the branchwires w1, w2 and w3 are connected in advance through the connectors c1,c2 and c3.

The covering board B in the foregoing state is combined with the doorframe A of a motor vehicle in the production line of motor vehicles, andthe branch wires w4 and w5 are connected to a power wind motor 4 and anautomatic door locking solenoid 5 within the door frame A through theconnectors c4 and C5. At the same time, an engaging portion G', at thewater proofing portion such as the grommet G, in the bundled leading-outportion W' is pushed sideways into a mounting groove 66 formed in an endportion of the door frame at the hinge mounting side for engagement, andis fixed thereto by machine screws 68 through mounting holes g5 and 6a.Thereafter, the covering board B is fixed to the door frame A to causeit to intimately contact an internal side flat portion g4 of theengaging portion G' for obtaining a satisfactory water-proofingarrangement (FIG. 38).

In a modified embodiment shown in FIG. 40, the door wire harness W is ofa bundled shape as shown in FIG. 41. In this embodiment, the door wireharness W is wired within a groove 67 formed in the door frame A. Theengaging portion G' of the grommet G provided at the end portion of thewire harness W is engaged in the mounting groove 66 formed in the doorframe A, and thereafter, the covering board B is mounted to form awater-proofing portion.

In a modified embodiment shown in FIG. 41, the grommet G is providedwith mounting flange G6 with holes displaced at the end thereof. Thegrommet G and the covering board B can be fixed to the door frame A byone action if the grommet G is fixed to the covering board B byengagement means, such as a clip 69, pushed into the holes in thecovering board B.

In any of the foregoing embodiments, wires are attached one by one tomounting means such as the covering board B, the wire harness wiringboard B1 of the covering board B, the electric equipment mounting boardsection BI of the covering board B, internal side board section A or themounting board X to form a wire harness thereon. However, the wireharness may be integrally produced beforehand, independent of the abovemounting means as shown in FIG. 42. In other words, said wires W areconnected to each other in a parallel flat fashion by heat melting theinsulation covering of the wire or via adhesive layer. Further, areinforcing plate 12 may be attached to one end portion of the connectedwire bundle, so as to be fastened by a tape 13 or the like, whereas ametal protector 14 having fixture holes 14a is attached to the other endportion thereof to be fastened by tape 13. The thus formed wire harnessis attached to the above mentioned mounting means.

As described in the foregoing, a wire harness mounting structure for amotor vehicle door comprises a door frame and planar mounting meansdetachably attached to said door frame at an internal side of the motorvehicle, having a wire harness mounted thereon, said means extending ina plane generally parallel to said door frame. The mounting means iseither in the form of a covering board, or a combination of the coveringboard and an internal side board mounted between the vehicle door frameand the covering board, and is either integrally formed with thecovering board, or rigidly formed independent of the board, as in thecase of an internal side board. Since the door wire harness is flatlydisposed on the mounting means, such as a covering board which is to beattached to the internal side of a motor vehicle door, a part of thebranch wires are connected, in advance, to electric equipment providedat the covering board, etc.; the remaining branch wires are connected toelectric equipment provided within the door frame, and thereafter thecovering board is fixed to the door frame, thereby simplifying andaccelerating mounting work of the door wire harness in the productionline of motor vehicles. Furthermore, since the wire harness is flatlydisposed on the mounting means only limited space is required, andwiring work can be carried out linearly and by way of the shortestdistance, contrary to the conventional method wherein the wiring work iscarried out in such a manner as to require finding a remaining spaceduring wiring. Furthermore, since the door wire harness is fixed tomounting means having a constant shape, such as the covering board,there is little possibility that the branch wires will be entangled whenit is transported, stored, and mounted to the door frame. In addition,even if it is used in circumstances under severe vibration, the wireharness can be held stably.

Although the present invention has been described in its preferred formswith a certain degree of particularity, it is understood that thepresent disclosure of the preferred forms has been made only by way ofexample and that numerous changes in the details of construction andarrangement of parts may be resorted to without departing from thespirit and the scope of the invention as hereinafter claimed. Also, inthe above embodiments, the wire harness is mounted to a motor vehicledoor, the invention can of course be applied to other cases in whichother wire harnesses are mounted to the inside of the vehicle body.

I claim:
 1. In a wiring system including a wire harness mountable on theframe of a hinge-mounted motor vehicle door and terminating at the hingemounting end of the door frame in a bundled leading-out portion, saiddoor frame having an inner side surface joined to a hinge mounting endwhich has internal and external side surfaces which with said inner sidesurface defines a corner portion, structure for fixing the leading-outportion of the wire harness to the hinge mounting end of said door framecomprising:an opening formed in said inner side surface of said doorframe which communicates with a groove formed in said hinge mounting endat said corner portion of said door frame, and a waterproof grommethaving first and second external flanges and an integral groove portionbetween said flanges dimensioned to be received in the groove formed insaid hinge mounting end, said grommet surrounding said leading-outportion of the wire harness and being supported on its groove portion inthe groove formed in said hinge mounting end and by said first andsecond flanges engaging said internal and external side surfaces,respectively, of said hinge mounting end thereby to fix the leading-outportion of the wire harness to the door frame at its hinge mounting end.